System and methods for handling drilling pipe

ABSTRACT

The invention provides a modular pipe handling system comprising a lift arm assembly including a base member and a lift arm mounted on the base member. The lift arm is pivotable between a horizontal and vertical position. The lift arm further comprises at least one clamping system for clamping a length of pipe to the lift arm, to allow movement of the pipe between the horizontal and vertical positions. The base member includes a leveling system associated therewith for independent leveling of the base member and corresponding lift arm relative to a drilling rig with which the pipe handling system is used. The base member may also include a positioning system for positioning of the base member a predetermined distance from the drilling axis of a predetermined drilling rig, wherein the positioning system is adaptable to vary the distance from the drilling axis. The base member includes a positioning system for positioning of the base member relative to a sub-base on which a drilling rig is selectively positioned during a drilling operation. The sub-base includes a rig indexing system for positioning of a drilling rig at a predetermined position thereon, and the location of the based member can be modified.

FIELD OF THE INVENTION

This invention relates to an improved system and methods for lifting and positioning drill pipe or other tubulars for use in conjunction with a drilling rig for drilling a borehole. The system and methods provide a modular system and methods for use with different types of rigs, and is adaptable for interchangeable use with various equipment and drilling site environments. The system and methods allow pipe to be easily moved from a horizontal position at an intermediate level to a raised position aligned with the drilling axis of a drilling rig.

BACKGROUND OF THE INVENTION

A variety of drilling rigs have been developed for boring holes for various purposes, including stationary rigs and truck mounted rigs for example. For example, drill rigs with top head rotary drives require lengths of pipe to be positioned along the drilling axis of the rig to be driven by the top head rotary drive. In drilling operations, the handling of the drill pipe can pose problems, as such pipes must be properly and precisely positioning to tie into a drill string. Similarly, handling pipe as it is removed from a borehole is important for safe and efficient drilling. Typically, the drill pipe or rods are stored on racks or the like at an elevated position above ground level. Without a pipe handling system, the operation of a drilling rig can be unsafe, as such pipe is generally lifted into position via cabling and drilling personnel physically moving the pipe into position. There have been developed specialized systems associated with particular drill rigs, for lifting individual lengths of down hole pipe from a pipe rack to a position for tying into the drill string or for removal of pipe. Although prior lifting systems are generally more effective for handling pipe for that particular rig, a user does not have the ability to interchange such systems for use with other rigs, or adapt the system for use with a different rig or under different conditions and environments. Further, many rigs in use today do not have any pipe handling system, and are therefore potentially unsafe and cumbersome to use. It would be desirable to provide a system and methods which would allow such flexibility and expanded use of such systems. For example, a drilling operator may have several rigs for use as needed, and it would be desirable to provide a handling system which could be used with each without necessity that the rigs be of the same type. The ability to provide a pipe handling system with any drilling rig provides a safe and effective system for use in any drilling operation.

Further, prior handling systems have tended to be complicated and expensive, both to manufacture as well as maintain. As the prior systems are dedicated assemblies used with a particular rig, the systems use customized components adapted for the particular rig and its requirements. Due to this, maintenance becomes problematic, as any repairs may require long down times where the system is not usable. In such situations, the user of the system may be dependent on the original manufacturer for parts, which due to their custom nature, have long supply lead times. It would be desirable to provide a handling system where the design allows for significantly reduced manufacturing costs. It would also be desirable to provide a handling system where the maintenance is simplified and cost-effectively performed without necessity for significant down time of the system.

Based upon the foregoing and other reasons, it would be desirable to provide a pipe handling system and methods which overcome the deficiencies of the prior art.

SUMMARY OF THE INVENTION

Based on the foregoing, it is an object of this invention to provide an improved pipe handling system and methods which overcome the limitations or disadvantages of the prior art. Accordingly, an embodiment of the invention is directed to a modular pipe handling system comprising a lift arm assembly including a base member and a lift arm mounted on the base member. The lift arm is pivotable about a first end between a substantially horizontal position and a substantially vertical position. The lift arm further comprises at least one clamping system for clamping a length of pipe to the lift arm, to allow movement of the pipe between the horizontal and vertical positions. The base member includes a leveling system associated therewith for independent leveling of the base member and corresponding lift arm relative to a drilling rig with which the pipe handling system is used.

Another object of the invention is to provide a modular pipe handling system comprising a lift arm assembly including a base member and a lift arm mounted on the base member. The lift arm is pivotable about a first end between a substantially horizontal position and a substantially vertical position. The lift arm further comprises at least one clamping system for clamping a length of pipe to the lift arm, to allow movement of the pipe between the horizontal and vertical positions. The base member includes a positioning system for positioning of the base member a predetermined distance from the drilling axis of a predetermined drilling rig with which the pipe handling system is used, wherein the positioning system is adaptable to vary the predetermined distance from the drilling axis.

A further object of the invention is to provide a modular pipe handling system comprising a lift arm assembly including a base member and a lift arm mounted on the base member. The lift arm is pivotable about a first end between a substantially horizontal position and a substantially vertical position. The lift arm further comprises at least one clamping system for clamping a length of pipe to the lift arm, to allow movement of the pipe between the horizontal and vertical positions. The base member includes a positioning system for positioning of the base member relative to a sub-base on which a drilling rig is selectively positioned during a drilling operation. The sub-base includes a rig indexing system for positioning of a drilling rig at a predetermined position thereon, wherein the rig indexing system is selectively varied to accommodate different drilling rigs.

According to a further feature of the invention, the lift arm is provided with first and second clamping systems for clamping a section of pipe to the arm, and the spacing between the clamping systems is selectively modified for clamping of different lengths of pipe. A clamping member may be movable to accommodate different length pipes on the lift arm. Further, the lift arm itself may be formed in two or more sections, which can be interchanged with one another for selectively modifying the length of the lift arm and correspondingly the length of pipe which can be accommodated thereon. A lower arm section is pivotably mounted to the base member via a hydraulically actuated linkage, and one or more further arm sections are selectively attached to accommodate the desired length of pipe. Alternatively, the lift arm may be formed in telescoping sections, which are selectively movable relative to the lower arm section to modify the length of the lift arm.

The invention provides distinct advantages in providing a pipe handling system and methods which allow a great amount of flexibility for use with different drilling rigs and equipment. The pipe handling system is cost effective and maintenance is facilitated by the use of off-the-shelf components which are readily available via a plurality of third party suppliers.

This provides the user with the ability to easily obtain parts if needed for repair, to minimize any down time where the handling system is not usable, and improving the safety of operation.

These and other objects and advantages of the invention will become apparent upon a further reading of the description of embodiments thereof in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic elevational front schematic view of a pipe handling system according to an embodiment of the invention, showing the lift arm thereof in a down position.

FIG. 2 is a schematic side elevational view of the pipe handling system according to an embodiment of the invention as shown in FIG. 1, with the lift arm in an up position.

FIG. 3 is a top elevational view of the pipe handling system as shown in FIG. 2.

FIG. 4 is an end elevational view of the pipe handling system as shown in FIG. 1, showing a leveling system associated therewith in both extended and retracted positions.

FIG. 5 is a side view of an alternate embodiment of a lift arm according to the invention.

FIG. 6 is a view of a clamping assembly according to an embodiment of the invention, shown in the open position.

FIG. 7 is a view of a clamping assembly shown in FIG. 6, shown in the closed position.

FIG. 8 is a partial perspective view of the area of coupling between a base member of the lifting assembly and a sub-base member on which a drilling rig is positioned.

FIG. 9 shows a series of various length coupling members or arms for use in coupling of the base member of the lifting assembly to a sub-base member on which a drilling rig is positioned.

FIG. 10 shows a partial exploded view of various mating components for use with the sub-base for positioning of a drilling rig thereon.

DETAILED DESCRIPTION OF THE INVENTION

Turning now to the drawings, FIGS. 1-3 are general views of a modular pipe handling system 10, for use with a drilling rig(not shown), according to an embodiment of this invention. In this embodiment, the drilling rig with which the system 10 may be used can be of the type such as produced by Ingersoll-Rand Company, W-N Apache Corporation, Schramm, Inc. and other types of drilling rigs, which are commonly used for drilling oil/gas wells, water wells or the like. The drilling rig typically includes a truck mounted mast which defines a drilling centerline, and a top-head drive unit. The pipe handling system 10 may be used in association with any of these types of rigs for example, and can be modified for use with other types of rigs, such as platform rigs or the like. The pipe handling system 10 comprises a base member 12, which is shown as a frame construction to form a floor or tub for use on the drill site. The base member 12 may be used for example as a storage area for tooling or other equipment during a drilling operation, or for transport. The base member 12 may have a length to accommodate a lift arm assembly 14 for safety of operation, although other configurations are possible. The lift arm assembly 14 is provided with first and second clamp members 16 and 18, and is pivotably mounted to the base member 12 adjacent a side thereof.

The pipe lift arm assembly 14 is used to selectively clamp a length of a pipe, and to move it between a substantially horizontal position as shown in FIG. 1, and a raised, substantially vertical position as shown in FIG. 2. In the position of FIG. 2, a length of drill pipe clamped into clamping members 16 and 18 will be aligned with the drilling centerline of the drill rig with which the pipe is to be coupled. The drill pipe may be moved into and out of the clamp members 16 and 18 by any suitable method, and typically will be moved from a storage rack adjacent the base member 12 via cabling or other suitable method, for inserting a length into a drill string, or moved back to the storage rack after being removed from the drill string and lowered via the lift arm 14. It should also be understood that the invention is not limited to drill pipe, but may also be used for handling of other pipes, tubes, drill collars, drill casing or the like.

The base member 12 is selectively coupled to a sub-base 20, which is used to position the drill rig in a predetermined position for drilling at a particular location. The drill rig is selectively positioned on the sub-base 20 via locating structures, and is then fixed into position to initiate a drilling operation. As seen in FIG. 3, the base member 12 and sub-base 20 are coupled about the position of the mousehole or drilling centerline, so the drill string can rotate freely. The sub-base 20 may be formed to have tracks 22 for the truck wheels, to allow positioning of the rig thereover. The sub-base further has a mounting plate 24, having locating pads 26 for placement of hydraulic jacks used to lift and level the rig relative to the sub-base 20 for drilling. The locating pads 26 are positioned relative to the location of the borehole to be drilled, to accurately position the rig for drilling. It should be understood that although this embodiment of the invention utilizes the locating pads to properly position the rig relative to the sub-base 20, other structure of the rig, common to any type of such rig, may be used. Once a rig is in position relative to sub-base 20, the coupling of the base member 12 to the sub-base 20 accurately positions the lift arm 14 in the proper position for moving the pipe into and out of the drill string during a drilling operation.

In a unique aspect of the invention, the movement of the lift arm 14 between the horizontal and vertical positions is performed in a simplified fashion, reducing the cost of the assembly and making maintenance easy. As seen in FIG. 4, the lift arm 14 may be constructed as a beam member having a top surface which carries the clamp members 16 and 18. The lift arm 14 is pivotally attached at its end to an upstanding support 30, and a pair of hydraulic cylinders 32 (one shown) are positioned on either side of the lift arm 14, and used to move the lift arm 14. The hydraulic cylinders 32 are selectively operated by a hydraulic control system (not shown), and are commonly available off-the-shelf parts to allow the user to simply and quickly repair, replace or maintain such parts, and avoid down time of the equipment.

As an alternative embodiment, the lift arm 14 may be formed in interchangeable sections as shown in FIG. 5, which allow the user to vary the length of the lift arm to properly support different length pipes. In such an embodiment, the lift arm 14 may be constructed of a series of interchangeable sections 15 and 17, which are selectively attached to one another and to a bottom section 19. The sections 15 and 17 can each in turn be a series of parts having predetermined lengths, which are the selectively arranged and coupled to one another to form a desired length arm 14. A universal mounting plate 21 or other suitable arrangement for coupling the sections 15 and 17 together may be used. Alternatively, the sections 15 and 17 may be formed as telescoping members, with section 17 selectively extendable between a minimum length and maximum length relative to section 15.

Also in this embodiment, the clamp members 16 and 18 are formed in a configuration to simplify use and maintenance, and are shown in open and closed positions in FIGS. 6 and 7. The clamp members 16 and 18 may be operated by a single hydraulic cylinder 38 of a standard off-the-shelf type, which is selectively operated by the hydraulic control system. As seen in FIGS. 6 and 7, the actuating rod 36 is coupled to a drive and linkage system for selectively opening and closing the clamps. The drive may simply be an off-the-shelf hydraulic cylinder 38 which is attached to linkage arms 40 on one end. A linking arm 43 attaches the two linkage arms 40 to one another for pivoting about the axis of this connection. The upper end of linkage arms 40 are connected to a second linkage arm 44, which are in turn connected to a movable clamp member 44 positioned in a housing 46. Upon actuation of the cylinder 38, the linkage arms 40 are moved between the positions as shown in FIGS. 6 and 7, which causes corresponding movement of the second linkage arms 44 to cause movement of the clamp members 44 into and out of engagement with a pipe situated in the clamping area 48. In this embodiment, the clamping area 48 is designed to accommodate all desired diameters of pipe or the like, and easily clamps any diameter without adjustment of the clamping system. Depending on the diameter of the pipe, the clamp members will move into engagement to securely clamp the pipe to the lift arm 14. It should be evident that the clamping assemblies 14 and 16 provide a very effective, yet simple mechanism, which is operated by a single hydraulic cylinder 38. The repair and maintenance of these systems is easily performed with off-the-shelf parts.

The clamps 16 and 18 may also be adapted to rotate to the right and left to facilitate loading of pipe into the clamping area 48. The hydraulic cylinder 34 is coupled to an actuating rod or bar 36, and is reversibly operated by reversal of the hydraulic fluid circuit to selectively rotate the bar 36 in a desired direction. The actuating bar 36 is coupled to each of the clamp members 16 and 18, in a manner that the clamps are selectively rotated with rotation of rod 36. This allows loading and unloading of pipe from either the left or right of the clamps 16 and 18 as may be desired. This may be accomplished is also accomplished using off-the-shelf hydraulic cylinders for ease of maintenance and repair. The position of clamp member 18 on actuating bar 36 may also be selectively varied to accommodate different length pipes,

Turning now to FIG. 8, the handling system of the invention provides an independent modular system which is independently stabilized apart from the drilling rig with which it is used. Associated with the base member 12, a pair of stabilizing jacks 50, one of which is shown in an extended stabilizing position and one of which is positioned in a stowed position. The stabilizing jacks 50 are used to level and stabilize the base member 12 and the lifting assembly for proper positioning and safe operation. The stabilizing jacks 50 may have a suitable extension and leveling capability to handle expected field conditions of a drill site. The ability to independently level and stabilize the lifting system 10 provides the capability to use the system 10 with any drill rig, as it is independently positioned relative thereto.

As also shown in FIG. 8, the base member 12 is coupled to the sub-base 20 by means of a pair of coupling arms 52, one of which is shown in a clamped position, and one shown in an uncoupled position. The coupling arms 52 are designed to position the base member 12 precisely relative to the sub-base 20, and positively connect the two for drilling. The coupling arms 52 are pivotally attached to the base member 12 by a support axle, and are easily removed for exchange as will be hereinafter described. The coupling arms 52 may be operated by a pair of hydraulic cylinders (not shown) so as to be movable to engage with coupling pockets 54 formed on the edge of sub-base 20. The pockets 54 may be provided on extending arms 56 to facilitate spacing around the borehole. To facilitate use with different drilling rigs, the coupling arms 52 may be interchangeable so as to space the base member 12 and sub-base 20 a predetermined distance relative to one another.

As seen in FIG. 9, a series of different length coupling arms 52 may be provided, each of which corresponds to use with a particular drilling rig, to allow the user to simply interchange the coupling arm 52 for use with whichever drilling rig they wish. It should also be recognized that alternatively, the extending arms 56 associated with the sub-base 20 could be provided as being interchangeable to selectively vary the spacing between the base member 12 and sub-base 20. The ability to alter the spacing between the base member 12 and sub-base 20 allows the alternative drilling centerlines of various rigs to be accommodated relative to the pipe handling system 10, in an easy and simply modified fashion.

Similarly, various rigs may have alternative support and/or leveling systems associated therewith, and the sub-base 20 according to this embodiment accommodates such variations to provide a modular system. As seen in FIG. 10, the sub-base 20 may be provided with rig support system adapted to a particular rig, and may have interchangeable locating pads 26 as previously described. The sub-base 20 may be formed with a pad receiving pocket 58 for each stabilizing and leveling pad associated with a rig, with a series of differently configured, interchangeable leveling pad receiving sections 60 provided for mating to a particular pad associated with the leveling jacks of a particular rig. If needed, multiple pockets 58 may be formed at different positions on the sub-base 20 to accommodate different rigs. As shown, the series of locating pads 26 can be configured such that sections 60 positively engage the leveling feet of a particular rig, which may be round, square/rectangular or any other suitable configuration or dimensions. The ability to interchange the structure which interacts with the leveling feet for proper positioning of the rig on sub-base 20 s enables the user to easily adapt the handling system 10 to any particular rig. It should also be understood that other appropriate common structures on the various types of rigs which would allow indexing and proper positioning of various rigs relative to the sub-base 20 and therefore to lifting arm assembly 12 are contemplated according to the invention.

From the foregoing, it should be apparent that the handling system and methods provide significant benefits that enable use for alternative drilling rigs and situations. The need for complex systems or customized components is eliminated and various modalities allow the system 10 to be used with various drilling rigs in various site environments. The system 10 provides a safe and easily operated system to effectively handle drill pipe or the like. The system 10 is easily maintained and serviced to effectively eliminate down time. It should be recognized that a wide range of modifications can be made to the embodiments described above. The invention is therefore not to be limited by the embodiments as described. It is therefore intended that the foregoing description be regarded as illustrative rather than limiting, and that the following claims, including all equivalents, define the scope of this invention. 

1. A modular pipe handling system comprising, a lift arm assembly including a base member and a lift arm mounted on the base member, wherein the lift arm is pivotable about a first end between a substantially horizontal position and a substantially vertical position, and further comprises at least one clamping system for clamping a length of pipe to the lift arm, to allow movement of the pipe between the substantially horizontal and substantially vertical positions, the base member including a positioning system for positioning of the base member a predetermined distance from the drilling axis of a predetermined drilling rig with which the pipe handling system is used, wherein the positioning system is adaptable to vary the predetermined distance from the drilling axis.
 2. The pipe handling system of claim 1, wherein the base member includes a leveling system associated therewith for independent leveling of the base member and corresponding lift arm relative to a drilling rig with which the pipe handling system is used.
 3. The pipe handling system of claim 1, further comprising, a sub-base on which a drilling rig is selectively positioned during a drilling operation, the sub-base having a rig indexing system for positioning of a drilling rig at a predetermined position thereon, wherein the rig indexing system is selectively varied to accommodate different drilling rigs.
 4. The pipe handling system of claim 1, wherein the system is selectively usable with drilling rigs of different types.
 5. The pipe handling system of claim 1, wherein the clamping system comprises at least one clamping mechanism which is movable to accommodate different lengths of pipe.
 6. The pipe handling system of claim 1, wherein the lift arm is formed of a plurality of sections to enable adjustment of the length of the lift arm.
 7. The pipe handling system of claim 1, wherein lift arm is actuated by a hydraulic linkage.
 8. The pipe handling system of claim 7, wherein the hydraulic linkage comprises at least one hydraulic cylinder attached to the lift arm.
 9. The pipe handling system of claim 6, wherein the plurality of sections are formed of different lengths which are selectively chosen to form a lift arm of a predetermined length.
 10. The pipe handling system of claim 9, wherein the sections are selectively coupled to one another by a universal mounting plate.
 11. The pipe handling system of claim 1, wherein the clamping system comprises at least one clamp member which is operated by a hydraulic cylinder.
 12. The pipe handling system of claim 11 wherein the hydraulic cylinder is attached to a linkage system coupled to the lift arm.
 13. The pipe handling system of claim 1, wherein the clamping system comprises at least one clamp member which is selectively rotatable.
 14. The pipe handling system of claim 13, wherein the clamp member is rotatable both to the right and left.
 15. The pipe handling system of claim 1, wherein the clamping system comprises at least one clamp which is selectively movable on the lift arm.
 16. The pipe handling system of claim 2, wherein the leveling system comprises at least one stabilizing jack capable of leveling the base member.
 17. The pipe handling system of claim 3, wherein the base member and sub-base are coupled by at least one coupling arm extending therebetween.
 18. The pipe handling system of claim 17, where the coupling arm engages a coupling pocket.
 19. The pipe handling system of claim 3, wherein the sub-base includes a rig indexing system to position a drilling rig at a predetermined position thereon.
 20. A modular pipe handling system comprising, a lift arm assembly including a base member and a lift arm mounted on the base member, wherein the lift arm is pivotable about a first end between a substantially horizontal position and a substantially vertical position, and further comprises at least one clamping system for clamping a length of pipe to the lift arm, to allow movement of the pipe between the horizontal and vertical positions, the base member including a leveling system associated therewith for independent leveling of the base member and corresponding lift arm relative to a drilling rig with which the pipe handling system is used.
 21. A method of handling pipe during a drilling operation comprising the steps of, positioning a drilling rig in a predetermined position on a sub-base, positioning a base member in a predetermined position relative to the sub-base, providing a lift arm in association with the base member, selectively using the lift arm to position a length of drilling pipe at the drilling axis of drilling pipe at the drilling axis of the drilling rig for tying into a drill string associated therewith. 